Winding generation method and device for flat wire permanent magnet motor with any number of layers, storage medium and flat wire winding

Abstract

The application relates to a flat wire winding generation method and device of a flat wire permanent magnet motor with any layer number, a storage medium and a flat wire winding, wherein the method comprises the following steps: step S1: introducing design parameters, wherein the design parameters comprise a stator slot number Q, a pole pair number p, a parallel branch number b and an every-pole-every-phase slot number q of the motor; step S2: designing a basic connection unit; step S3: based on the basic connection unit, a special connection unit is designed to connect the basic connection units to form elementary branches; step S4: judging whether the parallel branch number b of the motor is 1, if yes, all the elementary branches are connected in series, otherwise, step S5 is executed; step S5: judging whether the stator slot number Q of the motor reaches 2, if yes, all the elementary branches are connected in parallel, otherwise, step S6 is executed; step S6: changing the pitch of the special connection coil in the winding layout, meanwhile, the position of the wire-in and wire-out ends and the parallel branch rotating direction should be selected. Compared with the prior art, the application has the advantages of adapting to different pole-slot combinations and coil pitches, reducing manufacturing difficulty and cost and the like.

Description

Technical Field

[0001] This invention relates, and in particular, to a method, apparatus, storage medium, and flat wire winding for generating flat wire permanent magnet motor windings of arbitrary number of layers. Background Technology

[0002] Compared to traditional gasoline and diesel vehicles, electric vehicles (EVs) have significant advantages in environmental protection and energy conservation. As the core of the EV's drive system, the performance of the drive motor directly affects the EV's range and operational reliability. In recent years, flat wire technology has been increasingly applied to permanent magnet motors for electric vehicles due to its ability to significantly improve power density. Compared to traditional round wire windings, flat wire windings can significantly improve slot fill factor, thereby reducing copper losses. Furthermore, the lower end height and compact structure of flat wire windings effectively reduce the size and weight of the motor, while increasing torque density.

[0003] As electric vehicle drive motors gradually move towards higher speeds, the increased AC copper losses in flat wire windings will severely impact motor efficiency and reliability. To reduce AC copper losses, 4-layer, 6-layer, 8-layer, and even 10-layer flat wire winding designs have emerged in recent years. However, increasing the number of flat wire layers inevitably increases manufacturing complexity. Furthermore, while new flat wire winding topologies such as Litz wire windings, segmented conductors, and hybrid flat wire windings can effectively reduce AC copper losses, their manufacturing processes are complex, making mass production difficult. The design methods for flat wire windings differ from traditional round wire windings due to the diversity of their connection methods. When designing flat wire windings, not only must classical AC winding theory be satisfied, but the impedance balance of each branch must also be considered. Existing flat wire winding design methods are limited to even-numbered winding layers, with the basic connection unit being a double-layer wave winding. This requires jumpers with different pitches and same-layer connecting coils to connect each basic connection unit, undoubtedly increasing manufacturing costs. Moreover, the even-numbered-layer flat wire winding design method increases the difficulty of matching the torque-speed curve with the DC bus voltage, which is not conducive to serialized production design. Although designs with odd-numbered flat wire windings have emerged in recent years, they are limited to combinations of 5-layer flat wire windings and 8-pole 48-slot motors. Therefore, exploring general design methods for flat wire windings with arbitrary numbers of layers under different pole-slot combinations and coil pitches is of great significance. Summary of the Invention

[0004] The purpose of this invention is to provide a method, apparatus, storage medium, and flat wire winding for generating flat wire permanent magnet motor windings with an arbitrary number of layers.

[0005] The objective of this invention can be achieved through the following technical solutions:

[0006] A method for generating flat wire permanent magnet motor windings of arbitrary number of layers includes:

[0007] Step S1: Import design parameters, wherein the design parameters include the number of stator slots Q, the number of pole pairs p, the number of parallel branches b, and the number of slots per pole per phase q;

[0008] Step S2: Based on the design parameters, determine the rotation method of the flat wire winding, the number of slots and layers occupied by the basic connection unit, and the coil pitch of the basic connection unit, and design the basic connection unit.

[0009] Step S3: Based on the basic connection unit, with the goal of covering all slots and layers, design a special connection unit that connects the basic connection unit to form elementary branches;

[0010] Step S4: Determine if the number of parallel branches b of the motor is 1. If it is, connect all elementary branches in series; otherwise, proceed to step S5.

[0011] Step S5: Determine whether the number of stator slots Q of the motor reaches 2. If yes, connect all primary branches in parallel; otherwise, proceed to step S6.

[0012] Step S6: Change the pitch of the special connection coil in the winding layout to achieve commutation connection. At the same time, the position of the incoming and outgoing terminals and the rotation direction of the parallel branch should be adjusted to avoid crossing.

[0013] The flat wire coils in the basic connection unit are connected sequentially in all layers, with their directions reversed at the top and bottom layers via connecting coils on the same layer. Each basic connection unit begins and ends on the same layer.

[0014] The coil pitch of the basic connection unit obtained in step S2 is a whole pitch:

[0015] τ=Q / 2p

[0016] Where: τ is the coil pitch.

[0017] The special connection unit includes jumpers and in-layer connection coils, and the pitch of the special connection coils obtained in step S3 is all whole pitch:

[0018] τ=Q / 2p

[0019] Where: τ is the coil pitch.

[0020] In step S4, multiple elementary branches are connected in series using the end winding busbar.

[0021] In step S6, the commutation connection between parallel branches is achieved by alternating between full pitch and long or short pitch using the special connection coil.

[0022] The number of winding layers is set to either an even number or an odd number.

[0023] A flat wire winding is generated by the method described above.

[0024] An apparatus for generating flat wire permanent magnet motor windings of arbitrary number of layers includes a memory, a processor, and a program stored in the memory, characterized in that the processor executes the program to implement the method described above.

[0025] A storage medium having a program stored thereon, which, when executed, implements the method described above.

[0026] Compared with the prior art, the present invention has the following beneficial effects:

[0027] 1. The winding can be designed with any number of layers, which has a high degree of design freedom and helps to reduce the difficulty of matching the torque-speed curve with the DC bus voltage.

[0028] 2. It can adapt to different pole slot combinations and coil pitches, reducing the need for coils with different pitches, thereby reducing manufacturing difficulty and cost, and making it easy to achieve serialized production design. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the technical route of the present invention;

[0030] Figure 2 A schematic diagram of the method provided by the present invention;

[0031] Figure 3 A schematic diagram of the traditional even-layer flat wire winding design method;

[0032] Figure 4 This is a schematic diagram of a 6-layer flat wire winding connection according to an embodiment of the present invention;

[0033] Figure 5 This is a schematic diagram of a 7-layer flat wire winding connection according to an embodiment of the present invention;

[0034] Figure 6 A schematic diagram of a 6-layer flat wire winding connection under the traditional even-layer flat wire winding design method;

[0035] Figure 7 This is a schematic diagram of the crown side and welding side structure of a 6-layer flat wire winding according to an embodiment of the present invention;

[0036] Figure 8 This is a schematic diagram of the crown side and welding side structure of a 7-layer flat wire winding according to an embodiment of the present invention.

[0037] Figure 9 This is a schematic diagram of the main steps of the method of the present invention. Detailed Implementation

[0038] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments. These embodiments are based on the technical solution of the present invention and provide detailed implementation methods and specific operating procedures. However, the scope of protection of the present invention is not limited to the following embodiments.

[0039] A method for generating flat wire permanent magnet motor windings with arbitrary number of layers, such as... Figure 1 and Figure 9 As shown, it includes:

[0040] Step S1: Import design parameters, which include the number of stator slots Q, the number of pole pairs p, the number of parallel branches b, and the number of slots per pole per phase q;

[0041] The above design parameters are determined based on design requirements. Since they belong to existing technology, they will not be elaborated further.

[0042] Step S2: Based on the design parameters, determine the rotation method of the flat wire winding, the number of slots and layers occupied by the basic connection unit, and the coil pitch of the basic connection unit, and design the basic connection unit.

[0043] like Figure 2 As shown, the flat wire coils in the basic connection unit are connected sequentially in all layers. The direction is reversed at the top and bottom layers through in-layer connection coils. The basic connection unit begins and ends within the same layer. Clearly, this design of the basic connection unit can be used for both even-numbered and odd-numbered winding layers. For example... Figure 2 In the diagram, solid lines represent connections on the crown side of the flat wire winding end, and dashed lines represent connections on the welded side; the numbers in square brackets represent the coil pitch.

[0044] To reduce manufacturing difficulty, the pitch of the conventional coils in the basic connection unit can be designed as a whole pitch:

[0045] τ=Q / 2p

[0046] Where: τ is the coil pitch.

[0047] The pitch of the coils connected in the same layer can be designed as full pitch, long pitch, or short pitch.

[0048] In contrast, by Figure 3 It is known that the basic connection unit in the traditional even-layer flat wire winding design method is a double-layer wave winding form, in which the flat wire coil rotates up and down. Since the basic connection unit only occupies 2 layers of winding, this method cannot be used for the design of odd-layer windings.

[0049] Step S3: Based on the basic connection unit, with the goal of covering all slots and layers, design a special connection unit that connects the basic connection unit to form elementary branches;

[0050] The special connection unit includes jumpers and in-layer connection coils. The pitch of the special connection coils obtained in step S3 is always a whole pitch.

[0051] τ=Q / 2p

[0052] Where: τ is the coil pitch.

[0053] Step S4: Determine if the number of parallel branches b of the motor is 1. If it is, connect all elementary branches in series; otherwise, proceed to step S5.

[0054] When b=1, the parallel branch of the motor contains only one elementary branch, which is composed of several basic connection units connected in series. For example... Figure 2 As shown, in the arbitrary-layer flat wire winding design method, each basic connection unit only covers a portion of the stator slots. Different basic connection units should be connected using coils of the same layer to cover all stator slots of the motor. The pitch of the coils of the same layer can be designed as a whole pitch. In contrast, the basic connection unit in the traditional even-layer flat wire winding design method only covers two layers, therefore jumpers are needed to connect basic connection units of different layers, such as... Figure 3 As shown.

[0055] When b=1 and q=1, the design method of arbitrary layer flat wire winding contains only one elementary branch, while the traditional design method of even layer flat wire winding still contains two elementary branches. In this case, these two elementary branches should be connected in series through the same layer connecting coil. If there are multiple elementary branches in the motor, that is, when b=1 and q≥2, all elementary branches should be connected in series by the end winding busbar.

[0056] Step S5: Determine whether the number of stator slots Q of the motor reaches 2. If yes, connect all primary branches in parallel; otherwise, proceed to step S6.

[0057] When b≥2, the motor contains multiple parallel branches, formed by several elementary branches connected in parallel. To ensure a balanced voltage distribution among the parallel branches, commutation can be achieved by changing the pitch of special connecting coils (jump wires or same-layer connections). In the arbitrary-layer flat wire winding design method, since the same-layer connecting coils are always located at the top and bottom layers, simply changing the pitch of the same-layer connecting coils from a whole pitch to a long pitch or a short pitch, i.e., τ=Q / 2p±1, while keeping the pitch of other conventional coils whole, easily achieves commutation between parallel branches. For the traditional even-layer flat wire winding design method, commutation can be achieved by adjusting the jumper pitch. Simultaneously, reasonable input and output terminal positions and the rotation direction of the parallel branches should be selected to avoid crossing.

[0058] Step S6: Change the pitch of the special connection coil in the winding layout to achieve commutation connection. At the same time, the position of the incoming and outgoing terminals and the rotation direction of the parallel branch should be adjusted to avoid crossing.

[0059] By alternating the pitch of the conventional coil along the layer direction to either a long or short pitch, the full-pitch winding can be adjusted into a short-pitch winding, thereby effectively suppressing the back EMF harmonics and torque pulsation of the motor.

[0060] The following describes a specific implementation method for a flat wire permanent magnet motor winding design method of the present invention with reference to specific embodiments and accompanying drawings.

[0061] like Figure 4 , Figure 5 As shown, an embodiment of the present invention takes an 8-pole 48-slot permanent magnet motor with q=2 and b=2 as an example, and designs 6-layer and 7-layer flat wire winding layouts respectively. To achieve commutation connection and avoid crossing, the two parallel branches of the flat wire winding rotate in opposite directions along the circumference of the motor. Most conventional coils are full pitch, i.e., τ=Q / 2p=6, while the connecting coils in the same layer are long-pitch or short-pitch, i.e., τ=Q / 2p±1, thereby achieving commutation connection between parallel branches. All special connecting coils are located at the top and bottom layers, and the coil pitches of the top and bottom layers are 5 or 7 respectively. In this case, the required coil type does not increase compared to when b=1. In contrast, in the traditional even-layer flat wire winding design method, the pitch of the special connecting coils changes alternately in different layers, such as... Figure 6 As shown, the required coil type will double compared to when b=1, and the manufacturing cost will also increase accordingly.

[0062] Figure 7 and Figure 8 These are schematic diagrams showing the crown side and weld side of 6-layer and 7-layer flat wire windings, respectively. Both the input and output ends of the windings are located on the weld side. Figure 7 , Figure 8 As shown, the 6-layer and 7-layer flat wire windings have similar topologies, which is beneficial for achieving serialized production design.

[0063] If the aforementioned functions are implemented as software functional units and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this invention, or the part that contributes to the prior art, or a part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of this invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

Claims

1. A method for generating flat wire permanent magnet motor windings of arbitrary number of layers, characterized in that, include: Step S1: Import design parameters, wherein the design parameters include the number of stator slots Q, the number of pole pairs p, the number of parallel branches b, and the number of slots per pole per phase q; Step S2: Based on the design parameters, determine the rotation method of the flat wire winding, the number of slots and layers occupied by the basic connection unit, and the coil pitch of the basic connection unit, and design the basic connection unit. Step S3: Based on the basic connection unit, with the goal of covering all slots and layers, design a special connection unit that connects the basic connection unit to form elementary branches; Step S4: Determine if the number of parallel branches b of the motor is 1. If it is, connect all elementary branches in series; otherwise, proceed to step S5. Step S5: Determine whether the number of slots q per pole per phase of the motor reaches 2. If yes, then connect all primary branches in parallel; otherwise, proceed to step S6. Step S6: Change the pitch of the special connection coil in the winding layout to achieve commutation connection. At the same time, the position of the incoming and outgoing terminals and the rotation direction of the parallel branch should be adjusted to avoid crossing. In step S6, the commutation connection between parallel branches is achieved by alternating between full pitch and long or short pitch using the special connection coil. The basic connection unit includes flat wire coils connected sequentially in all layers. The flat wire coils reverse direction at the top and bottom layers through connecting coils in the same layer. The basic connection units all start and end in the same layer. The special connection unit includes jumpers and in-layer connection coils.

2. The method for generating flat wire permanent magnet motor windings of arbitrary number of layers according to claim 1, characterized in that, The coil pitch of the basic connection unit obtained in step S2 is a whole pitch: τ =Q⁄2p in: τ This refers to the coil pitch.

3. The method for generating flat wire permanent magnet motor windings of arbitrary number of layers according to claim 1, characterized in that, The pitch of the special connection coils obtained in step S3 is all whole pitch: τ =Q⁄2p in: τ This refers to the coil pitch.

4. The method for generating a flat wire permanent magnet motor winding with an arbitrary number of layers according to claim 1, characterized in that, In step S4, multiple elementary branches are connected in series using the end winding busbar.

5. The method for generating a flat wire permanent magnet motor winding with an arbitrary number of layers according to claim 1, characterized in that, The number of winding layers is set to either an even number or an odd number.

6. A flat wire winding, characterized in that, Generate by the method described in any one of claims 1-5.

7. A device for generating flat wire permanent magnet motor windings of arbitrary number of layers, comprising a memory, a processor, and a program stored in the memory, characterized in that, When the processor executes the program, it implements the method as described in any one of claims 1-5.

8. A storage medium having a program stored thereon, characterized in that, When the program is executed, it implements the method as described in any one of claims 1-5.

Images